FLEISCHWIRTSCHAFT international 6/2017

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46 Fleischwirtschaft international 6_2017 Organization Factory ERP optimallysupports the staff in their day-to-day operations. This applies to planning and control activities as well as to the operational tasks at the production and packaging machines. Transparency leads to more efficiency IT systems built on recipe-based meat production create practical added value Nothing goes without IT at today’s meat processing facilities. On the contrary.Ultimately,software and hardware serve as the key contributors to cutting costs, improving quality and becoming faster and more flexible. The prerequisite is that the IT systems, in particular ERP and MES, are seamlessly interconnected. The Belgian Colruyt group has realized this connection with the Factory ERP solution by CSB. By HermannSchalk Ifacompany has many stand-alone solutions that do not speak the same “language”, management loses the transparency of its business. Data is inconsistent, cannot be compared and, consequently,isnot very reliable. Moreover,costs increase: The lower the level of IT integration, the higher the expenses for operating diverse IT systems. This constantly calls for the installation of updates, adaptation of interfaces and implementation of improvements in several systems. In these cases, the software turns from helper into inhibitor –and from cost reducer into an increasing cost factor.Also for factory managers, business software can become a constraint if it does not meet industry-specific requirements or integrate machines. Classic “Group ERPs” are exhausted The importance of industry-specific functionalities in an enterprise resource planning (ERP) system is illustrated best by an example: The meat industry with its multitude of products and intricate manufacturing processes is extremely complex. Recipes are the heart of many meat processors. This is where all pieces come together,from product development and costing to material procurement, coverage planning and production. During production, variable factors like raw material quality, shelf life and proportions must be considered just as well as possibly resulting joint products that are processed further in other products. This poses areal challenge for the software system in use. Consequently,systems that have been developed specifically with the complex recipe-based meat production in mind have ahead-start. Only industry-specific systems with integrated recipe management are capable of managing recipes in an optimal way and thus planning the production, calculating the costs of aproduct, optimizing mixing proportions, identifying allergens, nutritional values and ingredients, as well as securing traceability.Other field examples calling for real industry know-how include the entry of operational data, as for instance unit quantities, quality grades and variable weight data, as well as batch processing during production and labeling or weigh labeling of the finished products. Classic ERP systems initially developed for unit production are exhausted when it comes to covering the production of foodstuffs of animal origin. In many cases, adequate key data is missing for proper production planning, statistical evaluations and weak spot identification. Pure MES systems have reached their limits The purpose of an MES (Manufacturing Execution System) is to enable the vertical integration of the shopfloor level with the planning level and to combine all production-related systems. These production management systems have an interface to the superordinate planning and automated data capture entities; however,the business administration “intelligence”islacking in such MES systems. While an ERP solution handles company-wide planning, control and logistics processes, aManufacturing Execution System handles industrial production. An MES is thus the executive branch of an ERP. Yet, it does not have all the ERP functionalities that are required for many practical applications in meat factories.
................................................ Fleischwirtschaft international 6_2017 49 Transparency leads to more efficiency Organization With the new software solution, Colruyt’s meat processing facility becomes faster and more efficient. It also enables full tracing of the manufactured products from incoming raw materials to outgoing finished specialities. This helps the management to keep the transparency of its business. In practice, software systems that have been developed specificallyfor the complex meat production have ahead-start. Forexample, when dealing with real-time stock management and, ultimately,itisabout customer service: Sales representatives should also be able to check the stock on hand and the production schedules so they can give accurate delivery guarantees. Forthis purpose, raw material availability needs to be checked automatically so that you can directly state for every incoming order when aparticular raw material is needed, and how much of it, in order to ensure that the material is supplied at the right time. The best of two worlds With the “Factory ERP” concept, CSB bridges the gap between Group ERP and MES for the meat industry.CSB Factory ERP comprises all vital ERP processes for the factory as well as MES functionalities, including interfaces to machines and equipment and to the Group ERP. The result is amore homogeneous and easy-to-manage IT landscape. Overall, company groups can control their various factories with the Factory ERP in an optimal manner,while becoming even more transparent and, ultimately, more efficient. Ameat processing company that can access any relevant details from rearing, slaughter,cutting, production and packaging at the press of a button usually will not only increase its transparency and productivity substantially.Higher information quality also enables it to enhance the identification of weak points, to respond quicker to customer requirements and to make decisions that are more reliable. Plus, it can establish complete documentation of its production processes. This is also abenefitmainly for vertically integrated enterprises that combine all stages of production under one roof. Integrated value chains create favorable conditions for assuring highest standards at all levels of production, food safety and traceability.Factory Source:CSB–System AG FLEISCHWIRTSCHAFT international 6_2017 Data exchange with the Group ERP as well as with machines and equipment is carried out via standardized interfaces. Optionally, interfaces marked with an asteriks are feasible in the Factory ERP.
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